SR-02 Thermal Measurement Guidelines
Transcription
SR-02 Thermal Measurement Guidelines
SR-02 7 Rebel LED 40mm Round Assembly Overview The SR-02 high brightness LED lighting assembly includes seven Rebel LEDs soldered to our 40mm round CoolBase. The LEDs can be connected in series or singly for full control of each LED making this assembly ideally suited for: • Flashlights • Bicycle Lights • Dive Lights • Lightsabers • Spot lighting • Task Lamps • Color tuned lighting • Fiber optic illuminators • Accent lighting The FR4 CoolBase features a highly efficient thermal design that matches or outperforms* standard aluminium MCPCB bases. This can directly translate into: Features: • LEDs can be configured for series or single operation • Longer LED life • Better color stability • Reduced cooling requirements The CoolBase makes it easy to mount the LED assembly a suitable heat sink and to work with the assembly using standard bench top soldering and hand tools. A single Vishay NTC 10K Thermistor (NTHS0805N02N1002J) is mounted to the board for continuous monitoring and foldback temperature control. SR-02 assemblies can be ordered directly from our website at www.luxeonstar.com/sr-02-7up. • Super efficient base design that matches or outperforms aluminium MCPCB bases • Integrated thermistor for continuous temperature monitoring • Available with all currently produced Rebel LEDs • Custom assemblies can be ordered with any color combination of LEDs Assembly Specifications • RoHS compliant Parameter • Pb free reflow soldered Value Base Type Base Thermal Performance (Not including LEDs) Finishing Solder Mask Color Solder Paste Max Operating Temperature (FR4 Base)1 Overall Dimensions (mm) Weight 1.6mm FR4 PCB 1.5°C/W Immersion Gold White AIM NC-258 No-Clean, Lead-Free 95°C 40D x 3.6H 6.7g • Extremely low thermal resistance 1 For maximum life, the FR4 board temperature must be kept below this value. * Results will vary depending on the quality of the dielectric material used in the MCPCB base. Quadica Developments Inc. 47 6th Concession Rd. Brantford, Ontario N3T 5L7 Canada Em: [email protected] Ph: 1-347-223-5077 For technical questions, please contact us by email at [email protected] The latest version of this document can always be downloaded from our website at www.luxeonstar.com/sr-02.pdf Document ID: SR-02 Revision: Feb 10, 2015 Page 1 SR-02 7 Rebel LED 40mm Round Assembly Power Drivers FlexBlock Wide Range DC Driver - Ideally suited for powering all 7 LEDs connected in series from voltages a low as 10VDC. BuckPuck/PowerPuck Drivers - Offers a variety of options for powering the SR-02 LEDs in parallel, series or parallel/series configurations. Secondary Optics The SR-02 assembly is compatible with Khatod and Polymer 7 LED optics available from the Luxeon Star LEDs website at: www.luxeonstar.com/7-LED-Optics Mounting & Cooling Use of this assembly requires careful attention to mounting and cooling to ensure that the junction temperature of the LEDs is kept well below the maximum rating as specified in the LED documentation published by Philips Lumileds. For optimal cooling, we recommend that the assembly be mounted to a suitable heat sink (aluminum or copper) that is exposed to open air using a thermal interface material such as our Bond-Ply© 100 pressure sensitive thermal tape or Arctic Silver™ thermal adhesive. The bottom of the LED assembly is electrically neutral, so it is not necessary to electrically isolate the LED base from the cooling surface. Bottom View The SR-02 has three mounting points for #4 screws. If you are using adhesive tape as a thermal interface, then we recommend that the assembly also be fastened to the heat sink using three mechanical fasteners. Before fastening the assembly to the heat sink, ensure that the two mating surfaces are perfectly flat and clean in order to maximize heat transfer to the sink. Be careful not to warp or distort the base by over tightening the fasteners. You need to confirm that the assembly is being adequately cooled by testing the temperature of each LED as described in the Measuring LED Junction Temperature section of this document. Failure to ensure that LED junction temperatures are kept below their maximum temperature rating will result in poor color rendering, early degradation of light output, and premature LED failure! Quadica Developments Inc. 47 6th Concession Rd. Brantford, Ontario N3T 5L7 Canada Em: [email protected] Ph: 1-347-223-5077 For technical questions, please contact us by email at [email protected] The latest version of this document can always be downloaded from our website at www.luxeonstar.com/sr-02.pdf Document ID: SR-02 Revision: Feb 10, 2015 Page 2 SR-02 7 Rebel LED 40mm Round Assembly Custom Colors For a small customization fee, the SR-02 assembly can be supplied with any color combination of Rebel LEDs mounted to the base. Visit our website at www.luxeonstar.com/sr-02-custom for more information and to order. Predefined Assemblies Once a custom LED assembly has been ordered, the assembly will be assigned a permanent part number and will be available for re-order from our website as a predefined assembly with no customization fees, no minimum order requirements and with quantity discounts. Visit our website at www.luxeonstar.com/sr-02-predefined for a full list of currently available Predefined Assemblies. Pad Connections PAD No’s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 +10 Connection LED1 - Cathode (-) LED1 - Anode (+) LED2 - Cathode LED2 - Anode LED3 - Cathode LED3 - Anode LED4 - Anode LED4 - Cathode LED5 - Cathode LED5 - Anode LED6 - Cathode LED6 - Anode LED7 - Cathode LED7 - Anode TSens TSens 9 10 11 J5 11 10 11 T 16 15 12 + LED6 T 12 13 12 J6 + 2 CB 1 Quadica Developments Inc. 47 6th Concession Rd. Brantford, Ontario N3T 5L7 Canada Em: [email protected] Ph: 1-347-223-5077 8 7 T LED4 CoolBase7 J3 7 SR-02.com LED3 Pb 3 LED2 J1 2+ + 8 J4 8 LED1 2 3 9 T1 T 13 T 14 LED5 TSens LED7 13 9 3 4 T 5 4 J2 5 6 6 T + 6 5 4+ For technical questions, please contact us by email at [email protected] The latest version of this document can always be downloaded from our website at www.luxeonstar.com/sr-02.pdf Document ID: SR-02 Revision: Feb 10, 2015 Page 3 SR-02 7 Rebel LED 40mm Round Assembly Series Operation To power all of the LEDs simultaneously (series operation), apply solder dots to the round series configuration pads (J1-J6). Connect a suitable current regulating driver to pad 14 (+) and pad 1 (-) as shown in Image 1. Image 1 Single Operation To power and control each LED separately, simply connect a suitable current regulating driver to each pad as shown in Image 2. Image 2 Quadica Developments Inc. 47 6th Concession Rd. Brantford, Ontario N3T 5L7 Canada Em: [email protected] Ph: 1-347-223-5077 For technical questions, please contact us by email at [email protected] The latest version of this document can always be downloaded from our website at www.luxeonstar.com/sr-02.pdf Document ID: SR-02 Revision: Feb 10, 2015 Page 4 SR-02 7 Rebel LED 40mm Round Assembly Measuring LED Junction Temperature The junction temperature of each LED on the assembly must be tested to be sure it is being adequately cooled. To make testing easy, each LED mounted on the SR-02 assembly includes a temperature test point that can be used to determine the LED junction temperature using the following procedure. Required Tools • Digital Multimeter • Temperature measurement meter • Thermocouple or thermistor with kapton tape and/or thermal adhesive epoxy - or • Hand held temperature measurement probe with a tip that is smaller than the temperature test pad on the LED assembly. Test Procedure 1. Enter the LED Typical Thermal Resistance Junction to Thermal Pad (°C/W) RθJ-C value from the Rebel LED datasheet into box B in the formula on page 7 of this document. 2. Ideally the temperature should be tested with the LED assembly mounted in the location where it will be operated. If the assembly will be in a difficult to reach location, then you will need to attach a thermocouple or thermistor to the assembly using kapton tape or Arctic Silver™ Thermal Adhesive epoxy so that the tip of the sensor is in direct contact with the temperature measurement point as shown in image 3. Be sure to allow the adhesive to fully cure and cool before testing. If the assembly is easily accessible, then you can use a hand held temperature probe to measure the test point temperature. Ensure that the tip of the temperature sensor is in direct contact with the test point pad. Image 3 Apply a small amount of epoxy to encapsulate the entire tip of the sensor. Image 4 Quadica Developments Inc. 47 6th Concession Rd. Brantford, Ontario N3T 5L7 Canada Em: [email protected] Ph: 1-347-223-5077 For technical questions, please contact us by email at [email protected] The latest version of this document can always be downloaded from our website at www.luxeonstar.com/sr-02.pdf Document ID: SR-02 Revision: Feb 10, 2015 Page 5 SR-02 7 Rebel LED 40mm Round Assembly 3. If you are measuring the temperature with a hand held probe, hold the probe onto the temperature test point for at least 1 minute after the LED assembly has reached its stable operating temperature. (Image 5) Applying a small amount of OMEGATHERM© 201 High Thermal Conductivity Paste, or heat sink thermal grease to the pad and probe tip will help to ensure you get an accurate reading. (Image 6) Ensure that the tip of the temperature probe is in firm contact with the test point pad. Image 5 Thermal paste around the pad and probe will help stabilize your temperature reading. Image 6 4. Power up the LED assembly and allow the temperature to stabilize for at least 5 minutes. 5. After the temperature measurement has stabilized, note the test point temperature and enter it in box A on page 7. 6. Measure the voltage across the LED you are testing (image 7) and note it in box C. Image 7 Quadica Developments Inc. 47 6th Concession Rd. Brantford, Ontario N3T 5L7 Canada Em: [email protected] Ph: 1-347-223-5077 For technical questions, please contact us by email at [email protected] The latest version of this document can always be downloaded from our website at www.luxeonstar.com/sr-02.pdf Document ID: SR-02 Revision: Feb 10, 2015 Page 6 SR-02 7 Rebel LED 40mm Round Assembly 7. Enter the current you are powering the LED at in box D. 8. Evaluate the completed formula to determine the junction temperature of the LED. A + (1.5 + Test Point Temperature °C ΨJ-S °C/W B RθJ-C )x( C x LED Forward Voltage Vf D * )= LED Forward Current If LED Junction Temperature °C * For maximum LED life, color stability and reliability, the calculated junction temperature must always be at or below the temperature shown in the Max Rec1 Junction Temp °C column of the specification table on page 8 of this document. More information about this junction measurement technique can be found in the LUXEON LED Thermal Measurement Application Brief (AB33) published by Philips Lumileds. 9. If you are powering all of the LEDs in series and the assembly is mounted to the center of a symmetrically shaped heat sink in open air, then it is typically only necessary to test a single LED to determine the junction temperature of all the LEDs. If you are powering the LEDs singly, or if the assembly is mounted to an unusually shaped heat sink, or will be used in an unusual operating environment, then you will need to test each LED to ensure that the junction temperature is below it’s safe operating point. Thermistor Temperature Measurement Every SR-02 assembly includes a single Vishay NTC 10K Thermistor (NTHS0805N02N1002J) mounted near the center of the board. This thermistor is intended for continuous monitoring of the assembly during operation and can be used as part of a foldback temperature control circuit to ensure that the assembly does not overheat. The thermistor does not replace the need to ensure that each LED is being adequately cooled by using the previously described test procedure. It is only intended to be used for in situ monitoring of the entire LED assembly. For details on how to measure the board temperature using the thermistor, please refer to our Onboard Thermistor Temperature Measurement Application Note. Quadica Developments Inc. 47 6th Concession Rd. Brantford, Ontario N3T 5L7 Canada Em: [email protected] Ph: 1-347-223-5077 For technical questions, please contact us by email at [email protected] The latest version of this document can always be downloaded from our website at www.luxeonstar.com/sr-02.pdf Document ID: SR-02 Revision: Feb 10, 2015 Page 7 SR-02 7 Rebel LED 40mm Round Assembly 3.58 [0.14] 1.60 [0.06] Assembly Drawing J1-J6 Solder dot pads for series operation 60 ° 0° 12 + J5 T + LED5 T TSens + LED6 T CB CoolBase ] 6] 4] P 1.3 2] PCD Ø25.8 ] 08 0. 0 [Ø Junction Temperature Test Point 0.0 0 [Ø1.0 CD 57 1. [Ø + [Ø [R 4.0 J2 04 .50 00 T CD .59] P 1 [Ø0 Ø3 + LED2 + 2. R1 0. J1 T Ø Ø14.9 Ø4 LED3 Pb T J3 SR-02.com LED1 LED7 + LED4 T1 T J6 Ø6.00 [Ø0.24] See Note 5 J4 Quadica Developments Inc. 47 6th Concession Rd. Brantford, Ontario N3T 5L7 Canada Em: [email protected] Ph: 1-347-223-5077 For technical questions, please contact us by email at [email protected] The latest version of this document can always be downloaded from our website at www.luxeonstar.com/sr-02.pdf Document ID: SR-02 Revision: Feb 10, 2015 Page 8 SR-02 7 Rebel LED 40mm Round Assembly Safety: The LEDs mounted onto this assembly produce highly intense points of light. Do not stare directly at the LEDs for any length of time. Restricted Use: Products produced or sold by Quadica Developments Inc. are not certified for use as critical components in life support devices, systems, nor in medical operating room or life rescue equipment. A critical component is any component of a life support device, system or medical/rescue equipment whose failure to perform can be reasonably expected to cause failure or malfunction of the life support device, system or medical operating room/life rescue equipment. Disclaimer: Although QUADICA DEVELOPMENTS INC. has attempted to provide the most accurate information and services data (hereinafter “Data”), the Data is provided “as is” and may contain errors. The entire risk of use of the data shall be with the user. QUADICA DEVELOPMENTS INC. makes no warranty, express or implied, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose, regarding the contents or correctness of the Data provided or the ability of the Data to meet the user’s needs or expectations. QUADICA DEVELOPMENTS INC. reserves the right to make changes and corrections without notice. You as the user agree to this disclaimer and the user agreement with the download or use of the provided Data. In no event shall QUADICA DEVELOPMENTS INC. be liable for any direct, indirect, special, incidental, exemplary, or consequential damages arising out of or related to the use of the Data, however caused, regardless of theory of liability, and whether or not QUADICA DEVELOPMENTS INC. has been advised of the possibility of such damage. This limitation shall apply notwithstanding any failure of essential purpose or any exclusive remedy. Quadica Developments Inc. 47 6th Concession Rd. Brantford, Ontario N3T 5L7 Canada Em: [email protected] Ph: 1-347-223-5077 For technical questions, please contact us by email at [email protected] The latest version of this document can always be downloaded from our website at www.luxeonstar.com/sr-02.pdf Document ID: SR-02 Revision: Feb 10, 2015 Page 9
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